Product Safety - Brake Stoplamp Switch

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.

If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the better that is being sent to owners, the owners are being instructed to contact the Buick Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

General Motors has determined that a defect which related to motor vehicle safety exists in certain 1989 and 1990 Buick Regal model vehicles. These vehicles may have a faulty brake stoplamp switch, which could result in the stoplamps not illuminating on application of the brakes. If this should occur in situations where a driver in a trailering vehicle is otherwise unable to recognize a braking action in sufficient time to respond appropriately, a vehicle crash could occur without prior warning. In some cases, failure of the stoplamp switch can result in the stoplamps staying on at all times.

In addition, in vehicles equipped with cruise control, a faulty stoplamp switch can result in resumption of the cruise control function upon release of the brake pedal. If this occurs, the cruise control feature can be disengaged by moving the cruise control switch to the OFF position, of by reapplying the brake. Once the vehicle speeds drops below 12-14 mph, the cruise feature will be automatically disengaged.

To prevent these conditions from occurring, an improved stoplamp switch will be installed on all involved vehicles.

Involved are certain 1989 and 1990 Buick Regal model vehicles built within the following VIN breakpoints:

Vehicles which Buick records indicate were previously repaired under warranty with Stoplamp Switch, P/N 10180504, are not included in this campaign.

Owners will be notified of this campaign on their vehicles by Buick Motor Division (see copy of owner letter included with this bulletin).

Dealers are to use the Dealer Communication System (DCS) to provide Buick Motor Division with subsequent Buick owner information. By reporting a change of owner or address of a vehicle in campaign status over the DCS, the need to send a CVAR form for that vehicle is eliminated. Terminal input instructions are covered in the DCS Manual under Section 9, page 9-J01A and B.

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.

If your dealership has vehicles involved in this campaign, you will receive the following items:

Involved vehicles have been identified by Vehicle Identification Number. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purposes is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

Customers with reimbursement claims should have their repair orders reviewed to determine if an improved design stoplamp switch (P/N 10180504) was installed at the time of repair.

Customer requests for reimbursement of previous repairs to correct a stoplamp switch condition are to be submitted according to the instructions included with this bulletin. Owners must submit ORIGINAL DOCUMENTATION that reasonably confirms the amount of unreimbursed repair expense, a description of the repair, the date of the repair, and the person or entity performing the repair.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O" order with NO special instruction code, but on an advise code (2).

GMSPO will preship each dealer five (5) stoplamp switch assemblies. These parts will be billed on the dealer parts account.

Important: ALL DEALERS ARE BEING SENT AN INSTRUCTIONAL VIDEO TAPE ON THE STOPLAMP SWITCH SETTING PROCEDURE. PLEASE BE SURE TO VIEW THIS VIDEO BEFORE PERFORMING THE PROCEDURE BELOW. FLEET WARRANTY STATIONS INTENDING TO PERFORM THIS CAMPAIGN MAY OBTAIN THIS VIDEOTAPE BY CALLING (313) 525-8200 BEFORE DECEMBER 14, 1990 AND ASK FOR HANK BOLSEN.

Stoplamp Switch Removal and Installation

1. Remove the air cleaner assembly and disconnect the negative battery cable.
2. Remove the left side insulator panel and slide the steering shaft protective sleeve towards the cowl.
3. Remove the air distribution tube and pull down.
4. Remove the retainer clip holding the stoplamp switch to the column bracket.
5. Disconnect the switch arm from the pedal by pushing the arm over an doff the brake pedal pin. Release the switch by pulling it down and releasing the top snap clip.
6. Disconnect the connector position assurance (CPA) locking pins from the four wire and two wire electrical connectors. (The two wire connector is not present on vehicles without the cruise control feature.)
7. Disconnect the four wire and the two wire connectors.
8. Remove the brake stoplamp switch assembly.
9. If the vehicle is equipped with cruise control, connect the two wire connector and the CPA locking pin to the new switch assembly.
10. Install the new switch assembly by pushing the switch up until seated into the top snap clip. DO NOT attach the switch arm to the pin on the brake pedal at this time.

Important: Make sure the brake switch is NOT adjusted (metal clip on the actuator is not engaged with the serrations on the bottom of the carrier) as shown in Figure 2.

11. Install the retainer clip which holds the switch to the steering column bracket.
12. Push the brake pedal down to the floor pan and install the switch arm over and onto the brake pedal pin.
13. Pull the brake pedal all the way rearward and listen for the switch to ratchet to the set position. AT LEAST THREE (3) CLICKS OF THE RATCHET MUST BE HEARD.
14. Connect the four wire connector and the CPA locking pin.
15. Position the steering shaft protective sleeve.
16. Reconnect the negative battery cable.
17. Inspect the stoplamp switch operation. If the stoplamps DO NOT operate, refer to the Stoplamp Switch Adjustment section of this bulletin. If the stoplamps DO operate, continue through Step 23.
18. Check the setting of the cruise vacuum dump, if so equipped. With the brake pedal at rest, make sure the plunger is fully seated into the barrel. If it is not fully seated, push the dump valve forward until the plunger is inside the barrel and then pull rearward on the brake pedal to properly set the valve. If the plunger is already fully seated into the barrel, the vacuum dump valve is already properly set and no further adjustment is required.
19. Reconnect the air distribution tube.
20. Reinstall the left side sound insulator panel.
21. Reinstall the air cleaner assembly.
22. Vehicles equipped with the 2.8L and 3.1L engines must have the following procedure performed to "relearn" the idle. This function was lost from the ECM's memory due to the loss of battery power.

22.1.

Place the air conditioning controls in the OFF position.

22.2.

Firmly apply the parking brake and block the drive wheels. Start the engine and shift the transaxle into DRIVE.

22.3.

Allow the engine to run a maximum of 10 minutes or until the engine cooling fan has cycled once, whichever occurs first.

22.4.

Shift the transaxle to PARK, then turn the ignition key to the OFF position for at least 5 seconds.

22.5.

Repeat Step B.

22.6.

Allow the engine to run for at least 5 minutes.

23. Install the Campaign Identification Label.

Stoplamp Switch Adjustment

Figures 1 through 5 may be helpful in performing this procedure.

1. Depress the brake pedal as far as possible and hold.
2. Using a stiff wire and a hooked end (refer to Figures 4 and 5), gently pull the switch set lever forward (toward the front of the vehicle), and listen for an audible click indicating release of the automatic adjuster.

Important: If no click is heard, release the brake pedal and repeat the procedure above.

3. After release of the automatic adjuster, pull the brake pedal all the way rearward. Listen for the switch to ratchet into the set position (setting the stoplamp switch). At least three (3) clicks of the ratchet must be heard.
4. Inspect the operation of the stoplamps. The stoplamps should operate at maximum brake pedal travel of 25 mm (1 in) and throughout the remainder of its travel. If the stoplamps DO NOT operate properly, repeat the switch adjustment procedure one more time. If the switch still fails to operate properly, refer to the Stoplamp Switch Adjustment Check chart (refer to Figure 4).

If the stoplamps do operate properly, return to Step 17 of the Stoplamp Switch Removal and Installation procedure above.

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner.

Apply the "Campaign Identification Label" only on a clean, dry surface.

Replaced parts must be held for disposition by Buick Zone or Branch contact personnel. Parts must have a claim tag attached showing the repair order and the VIN of the vehicle from which they were removed.

Use the "T" labor operation for reimbursement for previous customer paid repair. The Product Campaign must still be performed and the appropriate labor operation used.

1. Customer presents dealer with original paid receipts covering repairs.
2. Dealer completes a Repair Order (R.O.) showing the following:

-	Repair order date

-	Vehicle Identification Number

-	Current mileage

-	Owner's address

-	Attaches original owner's or dealer's paid invoices/receipts covering repair

-	Use Labor Operation Number T1690 and Failure Code 96

-	Enters total of reimbursement based on 100% of OWNER'S EXPENSE

3. Owner signs the repair order as acknowledgment of requested reimbursement amount.
4. Owner is given a copy of repair order.
5. Dealer assigns a Warranty Management System (WMS) authorization code to the claim and enters it on the WMS Authorization Log.
6. The dealer submits a claim to Buick for processing.
7. Dealer issues the owner a reimbursement check for the approved amount. The check number must be entered on the repair order and a copy of the check must be attached to the original paid invoices/receipts.
8. All supporting documentation must be available for review by Buick personnel as needed.

Important: Refer to Buick Service Policies and Procedures Manual, Section 1.6.1 for specific procedures for customer reimbursement verification.

Dear Buick Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has determined that a defect which related to motor vehicle safety exists in certain 1989 and 1990 Buick Regal model vehicles. These vehicles may have a faulty brake stoplamp switch, which could result in the stoplamps not illuminating on application of the brakes. If this should occur in situations where a driver in a trailering vehicle is otherwise unable to recognize a braking action in sufficient time to respond appropriately, a vehicle crash could occur without prior warning. In some cases, failure of the stoplamp switch can result in the stoplamps staying on at all times.

In addition, in vehicles equipped with cruise control, a faulty stoplamp switch can result in resumption of the cruise control function upon release of the brake pedal. If this occurs, the cruise control feature can be disengaged by moving the cruise control switch to the OFF position, of by reapplying the brake. Once the vehicle speeds drops below 12-14 mph, the cruise feature will be automatically disengaged.

To prevent these conditions from occurring, an improved design stoplamp switch will be installed on your vehicle. This service will be performed for you at no charge .

Please contact your Buick dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately fifty (50) minutes. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

If you have already experienced this condition and paid for all or part of the repair, you may request reimbursement through your Buick dealer. When doing so, you should present the dealer with documentation which reasonably confirms the amount of unreimbursed repair expense, the date of repair and the person or entity performing the repair.

When you make your reimbursement request, your repair order will be reviewed to assure that an improved design stoplamp switch was installed. If another switch was used for the repair, it will need to be replaced and a service date to perform this campaign should be scheduled. If the improved design part was installed, your vehicle already has the required part and no further action is necessary. In either case, a claim for reimbursement of the prior repair may be filed.

Your Buick dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Buick Customer Assistance Center by calling 1-800-521-7300.

After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, DC 20590 or call 1-8424-9393 (Washington D.C. resident use 366-0123).

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

Buick Motor Division

General Motors Corporation

Enclosure